Smart sensor networks deliver real-time quality control for fluid processes, by Emily Newton, www.revolutionized.com
Modern fluid management carries strict monitoring requirements. While crucial, these workflows can be time-consuming, inefficient and expensive, especially given the need for frequent testing. Facilities can work around these obstacles by deploying smart sensors for process control.
Internet of Things (IoT) technologies offer a promising alternative to manual control methods and conventional automation. Smart sensors gather data in real time before connecting wirelessly to other devices, opening the door to several needed process improvements.
Applications of smart fluid sensors
Using smart sensors effectively starts with recognising where they are most valuable. The single most impactful application will vary between organisations, but fluid management workflows can benefit from IoT systems in a few key areas.
Real-time testing
The most straightforward use of smart sensors for process control is to test fluid conditions in real time. Drinking water must adhere to maximum contaminant levels in 95% of samples from each reservoir, and pharmaceutical fluids often face even higher purity standards. Manually ensuring such cleanliness is time-consuming and error-prone, but IoT provides a better way.
Smart sensors can continually sample and analyse fluid contamination levels, pH balance, pressure and more without interrupting normal processes. This has two main advantages. First, facilities can ensure their water or other fluids meet acceptable standards with minimal disruption, enabling greater cost efficiency. Secondly, automation removes human error from the equation, resulting in more reliable tests.
Energy optimisation
IoT solutions can also automate equipment controls in response to the real-time data they collect. These automatic actions have several benefits, but one of the most important is that they minimise energy and resource consumption. Fluid processes that center on real-time information avoid waste from unnecessary cycling or electrical consumption.
Many smart sensors make small adjustments over time to ensure consistent operations while using as little energy as possible. Such optimisation is critical when complying with regulations, as industrial emissions standards are tightening and can produce cost savings. Similar applications can reduce material waste, such as using as few additives as possible to achieve desired fluid quality standards.
Flexible automation
Another valuable use case for smart sensors in process control is to make automated systems more flexible. In many cases, automation offers a trade-off between efficiency and adaptability. IoT connectivity can resolve the flexibility gap by controlling machinery in response to changing conditions, ensuring consistency even amid unpredictability.
For example, a conventional automated water management solution may send fluids through filters for a set number of cycles. However, contamination levels can vary, and filters can grow less efficient over time, so some cycles may fail to achieve the required cleanliness standards. Alternatively, it could run water more than necessary. IoT controls could prevent these outcomes by cycling it until real-time readings show the desired output and no more.
Predictive maintenance
Smart sensors can also improve equipment maintenance. A suboptimal repair schedule will lead to higher operational costs and resource consumption, but traditional, schedule-based upkeep often leads to unnecessary planned downtime from unneeded fixes. IoT offers a better path forward through predictive maintenance (PdM).
PdM predicts when machines will require repairs in the future by noticing subtle trends in their real-time operational data. Caring for equipment in response to these alerts instead of regularly scheduled downtime means all repairs reflect an actual need, minimising disruption. PdM also lowers costs by catching maintenance needs before they are outwardly evident, which prevents breakdowns and avoids complicated repairs.
How to deploy smart sensors for process control
Once organisations recognise how smart sensors can benefit their fluid process controls, they must realise that optimal results only come from informed implementation. Effective IoT usage follows a few common best practices.
Identify relevant use cases
The first step in using smart sensors for process control is determining which use case is the most appropriate for the facility. While any of the above four applications can be beneficial, which one has the biggest impact depends on the workflow. Identifying these company-specific opportunities is key to an effective rollout, as 92% of successful tech adopters say that clarity of objective and scope was the most relevant factor in their success.
Start by determining where current controls show the most room for improvement. Frequent repair issues and high maintenance costs may suggest PdM should be the business’s first IoT target. Alternatively, regular disruptions from testing or excessive energy costs make real-time testing a more relevant goal.
Ensure IoT cybersecurity
Once leaders identify a relevant use case but before they choose a solution to meet these demands, cybersecurity must come into the decision. IoT systems suffered over 112 million cyberattacks in 2022 alone, highlighting a critical need for higher security. This safety starts with choosing devices from a reliable provider that feature strong built-in protections, such as multifactor authentication and data encryption.
Smart sensors must also use their own network, separate from other devices and data. This segmentation minimises the risks of an attacker moving from an IoT endpoint to more sensitive systems. Automated network monitoring, automatic firmware updates and regular penetration testing are also ideal.
Train employees for the new system
Using smart sensors in process control means related workflows must adapt. Consequently, any new technologies must also come with a training adjustment. Communicate with employees about how their roles might change and train them on these new steps before fully integrating the IoT solutions.
Any workers interacting with smart endpoints must also learn cybersecurity best practices like good credential management and how to spot phishing attempts. Upskilling employees to learn how to manage complex IT networks may also be necessary to enable larger-scale tech deployments in the future.
Monitor results and expand slowly
After implementing a smart solution, businesses should keep a close eye on the results. IoT projects can be difficult to get right on the first attempt, so ongoing monitoring and adjustment is necessary.
Any failures, successes or unexpected situations deserve a detailed record. In addition to informing where an IoT system can improve, this data can serve as a baseline for future smart deployments. Learning from the past to avoid similar mistakes down the line is key to expanding IoT infrastructure effectively.
Smart sensors are crucial for modern process control
Today’s fluid process control workflows must adhere to strict quality, efficiency and reliability standards. The best way to meet these rising demands is to capitalise on technology. Amid this technological shift, familiarity with smart sensors is becoming less of a competitive edge and more of a necessity.
The June issue of Process & Control looks at the topic of sensors & measurement.
